Engineering Standard

SAES-W-019 10 October 2011

Girth Welding Requirements for Clad Pipes
Document Responsibility: Welding Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................ 2
2 Conflicts and Deviations................................ 2
3 References.................................................... 2
4 Approved Welding Processes....................... 3
5 Welding Procedure Qualification................... 4
6 Welder and Welding Operator Qualification.. 7
7 Production Welds.......................................... 7
8 Post Weld Heat Treatment............................ 8
9 Inspection...................................................... 8

Annex A............................................................... 10

Previous Issue: New Next Planned Update: 10 October 2016

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Primary contact: Rao, Sanyasi on +966-3-8760242

Copyright©Saudi Aramco 2011. All rights reserved.

Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

1 Scope

1.1 This standard specifies the girth welding requirements for CRA clad pipelines
and piping for both onshore and offshore application. These requirements are in
addition to the requirements of ASME SEC IX.

1.2 This standard does not apply to:

a) Weld overlaying of pipes and piping components
b) Fabrication of clad piping spools

2 Conflicts and Deviations

2.1 Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Materials Systems Specifications (SAMSSs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.

3 References

Unless stated otherwise, all Codes, Standards, and Drawings referenced in this Standard
shall be of the latest issue (including revisions, addenda, and supplements) and are
considered a part of this Standard.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-324 Ceryification Review and Registration of Project
Welders

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME SEC IIC Welding Rods, Electrodes and Filler Metals

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

ASME SEC V Nondestructive Examination

ASME SEC IX Welding and Brazing Qualifications

American Society for Testing and Materials

ASTM E92 Vickers Hardness of Metallic Materials

American Welding Society, Inc.

AWS A5.32 Specification for Welding Shielding Gases

NACE International/International Standardization Organization

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-
Materials for use in H2S-Containing
Environments in Oil and Gas Production

4 Approved Welding Processes

The following processes are approved for use with the restrictions and requirements as
listed below:

4.1 SMAW, GTAW and GMAW are approved welding processes. Other welding
processes can be used if approved by CSD.

4.2 Root pass welding shall be carried out using GTAW process. Alternative
welding processes can be used if approved by CSD.

4.3 It is acceptable to use GMAW process for the root pass subject to the following
conditions:
(i) Mode of metal transfer is restricted to modified short circuit transfer
(ii) It is demonstrated that root pass can be made without spatter
(iii) The range of welding parameters (I, V, Pulsing Parameters and Travel
Speed) used in the PQR’s are considered essential variables
(iv) Type and make of welding machine is considered an essential variable

5 Welding Procedure Qualification

5.1 All welding procedures shall be qualified in accordance with latest edition of
ASME SEC IX.

5.2 Welding procedures shall be qualified for each project using the pipes intended
for the project.

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

5.3 Qualification of the welding procedures must be carried out during the presence
of welding engineer from CSD. A minimum of 4 weeks’ notice shall be given
to CSD. CSD may delegate this responsibility to project inspection or third party
inspection agency.

5.4 The following welding variable shall be considered as essential variables:

a) Bevel design, with tolerance, intended for the production welds
b) Increase in mismatch from that used in the PQR test coupon
c) Brand name of welding consumables, unless approved by CSD
d) Diameter, wall thickness and grade of the test coupon
e) Heat input of root pass and hot pass (range of heat input can be qualified
by qualifying multiple PQRs)
f) Minimum number of layers for which purging is to be maintained (see
paragraph 7.4)
Commentary:

See paragraph 4.3 (ii) and (iii) for additional essential variable.

5.5 All welding consumables used shall be classified as per AWS/ASME SEC IIC
or equivalent classification if approved by CSD. Welding consumable selection
shall be as per Table 1 below. Other welding consumables can be used if
approved by CSD.

Table 1

Clad Root Pass and Hot Pass Rest of the Passes

Type
Covered
Pass Bare Wire Bare Wire Covered Electrode
Electrode
316L ER316L NA ER309LMo E309MoL

316L ER309LMo/ERNiCrMo-3 NA ER309LMo/ERNiCrMo-3 E309MoL/ENiCrMo-3

825 ERNiCrMo-3 NA ERNiCrMo-3 ENiCrMo-3

625 ERNiCrMo-3 NA ERNiCrMo-3 ENiCrMo-3

5.6 Complete girth welding shall be carried out using corrosion resistant alloy (CRA)
welding consumable. It is not acceptable to weld a buffer layer with pure iron
welding consumable followed by welding with carbon steel electrodes/filler wire.

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

5.7 If there is access for welding from the ID side, it is acceptable to cut back the
CRA layer and carry out girth welding using a carbon steel electrode. CRA
layed can subsequently be deposited by weld overlay.

5.8 Duplex/Super duplex stainless steel consumables shall not be used for girth
welding unless approved by CSD.

5.9 PQR test coupon should be tested by not destructive testing (RT or UT).
The selection of NDT method should be identical (including manual or
automatic NDT) to the NDT method proposed for production welds.

5.10 Tensile testing on the PQR test coupon shall be carried out after removing the
CRA material unless CRA thickness is included in the design calculation for
bearing the pressure.

5.11 The PQR shall include the following additional tests:

a) Chemical composition shall be carried out at a depth of 2.0 and 2.5 mm
from the ID CRA surface. The chemistry shall be within the range
specified in ASME SEC IIC or AWS specification. In the case of alloy
N06625, the iron content shall not exceed 6%. The PREN
(%Cr+3.3%Mo+16%N) as calculated from the above chemical analysis
shall be as per Table 2 below.

Table 2

Grade PREN (min.)

316/316L 24
N08825 42
N06625 45

b) Hardness testing shall be carried out on the weld cross section as per
Annex A for sour service only. Test shall be carried out using 5 kg or
10 kg loads in accordance with ASTM E92 using the Vickers method.
Tests shall be conducted on weld cross sections removed from near the
6 and 12 O’clock positions. The cross sections shall be etched to reveal
the weld, HAZ and fusion zone. Hardness of the carbon steel shall not
exceed 248 HV10. Hardness of the CRA weld, HAZ and base metal
should not exceed the limits specified in NACE MR0175/ISO 15156.
Commentary:

If any hardness readings close to the fusion zone between the carbon steel
and CRA weldmetal significantly exceed the acceptance criteria, the test
can be considered acceptable if it can be proven that the reading is from a

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

location in the intermediate mixed zone/unmixed zone.

c) Corrosion test shall be carried out as per Table 3 below. Corrosion

specimens shall be prepared by removing the backing carbon steel by
milling or by other means. Specimen shall be taken from the location of
maximum mismatch and the thickness of the specimen shall not be less
than 2.0 mm.

Table 3

Steel Grade Corrosion Test Test Conditions Acceptance Criteria

ASTM G48 Test temperature: 22C
UNS N08825 No pitting at 20X magnification
Method A Test duration : 72 hours
ASTM G48 Test temperature: 50C
UNS N06625 No pitting at 20X magnification
Method A Test duration : 72 hours

Notes:
a. The surfaces of the specimens shall be in the “as welded” condition. No surface treatment like
grinding, buffing or pickling is allowed.
b. Cut edges shall be prepared according to ASTM G48.
c. Weight loss requirement does not apply to weld overlays.
d. The corrosion test sample shall include the clad base material with weld at the center. The CRA weld
reinforcement shall not be ground flush. In case of lined pipe, the CRA liner as well as the weld
overlay shall be tested.

5.12 Repair welding procedures shall be qualified separately for both through
thickness and partial thickness repairs. Through thickness repairs using SMAW
process is not acceptable.

5.13 All welding procedures, including procedures for repair, must be reviewed and
approved by Welding Standards Committee. Project welding engineers
representing CSD are not authorized to approve welding procedures intended for
girth welding of clad pipes.

6 Welder and Welding Operator Qualification

6.1 All welders/welding operators shall be qualified in accordance with the

ASME SEC IX and SAEP-324.

6.2 The test records of all welders and welding operators shall be available at all
times at the work location for review by Saudi Aramco Inspection. Performance
qualification tests shall not be performed on production joints on Saudi Aramco
work.

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

7 Production Welds

7.1 The CRA surface shall be adequately protected from cutting debris and
contamination with carbon steel during plasma cutting and beveling operation.

7.2 The CRA surface shall not directly contact copper-based backing shoe material
at any time during the welding or laying process.

7.3 The fit-up of the welds may be inspected and cleared by Saudi Aramco project
inspection.

7.4 Back purging shall be carried out using inert gas conforming to AWS A5.32
until the completion of root and hot pass. It is not acceptable to use nitrogen as
a purging gas. The back purge shall reduce the oxygen to a level below 0.05%.
An oxygen analyzer should be used for continuous monitoring of the oxygen
content inside the pipe during purging. A spray purging system may be used if
demonstrated by a PQR.

8 Post Weld Heat Treatment

Post weld heat treatments (PWHT) shall be carried out if required by the applicable
codes. A written procedure describing the PWHT requirements shall be submitted to
CSD for review and approval.

9 Inspection

9.1 Saudi Aramco representatives shall have free access to the work at all times.

9.2 Saudi Aramco shall have the right to inspect the fabrication at any state or stage
and to reject material or workmanship which does not conform to the specified
requirements.

9.3 Nondestructive testing (NDT) procedures shall be established in accordance

with ASME SEC V. A written procedure for each inspection method and
technique, including acceptance criteria, to be used shall be submitted to
Inspection Department for approval. Qualification of the procedure by the
contractor may be required, as determined by Saudi Aramco Inspection.
Inspection procedures in conformance with other standards are acceptable only
with the approval of Inspection Department.

9.4 All NDT personnel, including personnel for visual inspection, shall be qualified
as a minimum to Level II by ASNT or an equivalent certification body.

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

Commentary:

The ASNT term Nondestructive Testing (NDT) has been used in this standard
and shall be considered synonymous with the ASME term Nondestructive
Examination (NDE).

9.5 Root pass of all welds shall be visually inspected with the aid of a camera or
vision sensor. Visual Examination shall ensure uniform and adequate
penetration. Weld imperfections in the root such as lack of fusion, porosity,
internal spatter, etc., are not acceptable irrespective of the extent or size of the
imperfection. The contractor shall submit the visual inspection procedure along
with the acceptance criteria to CSD for approval.

9.6 All welds shall be 100% inspected using RT or automatic UT. If the contractor
proposes to use automatic UT, the procedure and equipment shall be
demonstrated to Saudi Aramco NDT specialist preferable during qualification of
PQR. This verification can be done at any location convenient to the contractor
with prior advanced intimation to Saudi Aramco Inspection Department and
CSD.

9.7 Acceptance criteria for RT and UT shall be as per the applicable design code.
However, no welding imperfections, as revealed by visual inspection are
acceptable in the root pass as stated in paragraph 9.5 above.
Commentary:

The contractor may choose to have an intermediate NDT station after the root
and hot pass to prevent complete cut off of welds due to root defects detected
during final NDT carried out after completion of girth welding.

9.8 In case of lined pipe, the inside of the pipe shall be inspected for possible
collapse of liner after completion of girth welding. Inspections shall be carried
by passing a scraper (buckle detector) through the pipe.

9.9 Positive Material Identification (PMI) shall be conducted on 10% of the girth
welds. Acceptance criteria shall be as per AWS/ASME SEC IIC with the
exception of iron content as specified in paragraph 5.11 a.

Revision Summary
10 October 2011 New Saudi Aramco Engineering Standard.

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Document Responsibility: Welding Standards Committee SAES-W-019
Issue Date: 10 October 2011
Next Planned Update: 10 October 2016 Girth Welding Requirements for Clad Pipes

Annex A

Hardness Testing for Procedure Qualification

1.5 MM

1.5 mm

Orientation and Location of Hardness Indentations

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